Photovoltaic module and module arrays

ABSTRACT

A photovoltaic (PV) module including a PV device and a frame, The PV device has a PV laminate defining a perimeter and a major plane. The frame is assembled to and encases the laminate perimeter, and includes leading, trailing, and side frame members, and an arm that forms a support face opposite the laminate. The support face is adapted for placement against a horizontal installation surface, to support and orient the laminate in a non-parallel or tilted arrangement. Upon final assembly, the laminate and the frame combine to define a unitary structure. The frame can orient the laminate at an angle in the range of 3°-7° from horizontal, and can be entirely formed of a polymeric material. Optionally, the arm incorporates integral feature(s) that facilitate interconnection with corresponding features of a second, identically formed PV module.

PRIORITY DATA

This application is a continuation of U.S. patent application Ser. No.12/492,802, filed Jun. 26, 2009, which claims priority under 35 U.S.C.§119(e)(1) to U.S. Provisional Patent Application Ser. No. 61/076,492,filed Jun. 27, 2008, entitled “Photovoltaic Module and Module Arrays”,and the entire teachings of which are incorporated herein by reference.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

This invention was made with Government support under Contract No.DE-FC36-07GO17043 awarded by the United States Department of Energy. TheGovernment has certain rights in this invention.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application also relates to U.S. application Ser. No. 12/492,640,now U.S. Pat. No. 8,065,844 issued Nov. 29, 2011, entitled “BallastedPhotovoltaic Module and Module Arrays” U.S. application Ser. No.12/492,680, now U.S. Pat. No. 8,061,091 issued Nov. 22, 2011, entitledPhotovoltaic Module Kit Including Connector Assembly for Non-PenetratingArray Installation” U.S. application Ser. No. 12/492,729 entitled“Photovoltaic Module with Removable Wind Deflector” and U.S. applicationSer. No. 12/492,838 entitled “Photovoltaic Module with Drainage Frame”all of which were filed on Jun. 26, 2009 and the teachings of each ofwhich are incorporated herein by reference.

BACKGROUND

The present disclosure relates to solar roof tiles. More particularly,it relates to photovoltaic modules adapted for rapid installation aspart of an arrayed, rooftop photovoltaic system.

Solar power has long been viewed as an important, highly viable,alternative energy source. To this end, substantial efforts andinvestments have been made to develop and improve upon solar energycollection technology. Of particular interest are industrial- orcommercial-type applications in which relatively significant amounts ofsolar energy can be collected and utilized in supplementing orsatisfying power needs.

Solar photovoltaic technology is generally viewed as the optimalapproach for large scale solar energy collection, and can be used as aprimary and/or secondary (or supplemental) energy source. In generalterms, solar photovoltaic systems (or simply “photovoltaic systems”)employ solar panels made of silicon or other materials (e.g., III-Vcells such as GaAs) to convert sunlight into electricity. Moreparticularly, photovoltaic systems typically include a plurality ofphotovoltaic (PV) modules (or “solar tiles”) interconnected with wiringto one (or more) appropriate electrical components (e.g., switches,inverters, junction boxes, etc.). The PV module conventionally consistsof a PV laminate or panel generally forming an assembly of crystallineor amorphous semiconductor devices electrically interconnected andencapsulated. One or more electrical conductors are carried by the PVlaminate through which the solar-generated current is conducted.

Regardless of an exact construction of the PV laminate, most PVapplications entail interconnecting an array of PV modules at theinstallation site in a location where sunlight is readily present. Thisis especially true for commercial or industrial applications in which arelatively large number of PV modules are desirable for generatingsubstantial amounts of energy, with the rooftop of the commercialbuilding providing a convenient surface at which the PV modules can beplaced. As a point of reference, many commercial buildings have large,flat roofs that are inherently conducive to placement of a significantarray of PV modules. In fact, utilizing an existing rooftop as the PVmodule installation site represents the most efficient use of space inthat the building/rooftop structure is already in existence, and thusminimizes the need for additional, separate structures necessary forsupporting the PV modules. While rooftop installation is thus highlyviable, certain environment constraints must be addressed. For example,the PV laminate is generally flat or planar; thus, if simply “laid” onan otherwise flat rooftop, the PV laminate may not bepositioned/oriented to collect a maximum amount of sunlight throughoutthe day. Instead, it is desirable to tilt the PV laminate at a slightangle relative to the rooftop (i.e., toward the southern sky fornorthern hemisphere installations, or toward the northern sky forsouthern hemisphere installations). Further, rooftop-installed PVmodules are oftentimes subjected to windy conditions, a concern that isfurther heightened where the PV laminate is tilted relative to therooftop as described above.

In light of the above, conventional PV module installation techniqueshave included physically interconnecting each individual PV module ofmodule array directly with, or into, the existing rooftop structure. Forexample, some PV module configurations have included multiple framemembers that are physically attached to the rooftop via bolts driventhrough the rooftop. While this technique may provide a more rigidmounting of the PV module to the rooftop, it is a time-consumingprocess, and inherently permanently damages the rooftop. Further,because holes are formed into the rooftop, the likelihood of waterdamage is highly prevalent. More recently, PV module configurations havebeen devised for commercial, flat rooftop installation sites in whichthe arrayed PV modules are self-maintained relative to the rooftop in anon-penetrating manner. More particularly, the PV modules areinterconnected to one another via a series of separate, auxiliarycomponents, with a combined weight of the interconnected array (andpossibly additional ballast and/or wind-deflecting fairings or “winddeflectors” mounted to one or more of the PV modules at the installationsite) serving to collectively offset wind-generated forces.

While the non-penetrating PV module array approach has beenwell-received, certain drawbacks may still exist. For example, a largenumber of parts are required, along with the logistical management ofthese parts, to facilitate non-penetrating, interconnected mounting ofan array of PV modules. In this regard, the arrangement of PV modules(e.g., number, location, and type) will vary for each installation site.Thus, the number and types of requisite, auxiliary mounting componentswill also vary, and must be accurately ordered and delivered to theinstallation site with the PV modules. Thus, considerable upfrontplanning is necessary. Along these same lines, installation requirementsfor several non-penetrating PV module formats entail wind-deflectingauxiliary components (e.g., a perimeter curb) that are configured orsized as a direct function of the resultant perimeter shape or geometryof the arrayed PV modules. Once again, substantial upfront planning mustbe performed in order to ensure that these wind-deflecting components,as well as other installation components, are provided to theinstallation site in forms that are properly sized and shaped inaccordance with the expected shape of the PV module array. Clearly, anyerrors in the upfront planning, miscommunication of the installationparameters, incorrect part list ordering, etc., can negatively impactand overtly delay the installation process. Further, where the auxiliaryinstallation components are packaged apart from the PV modules, as iscommon in the industry, it is highly difficult at best for theinstallation personnel to quickly recognize whether ordering and/orshipping errors have occurred. Instead, these errors only become evidentduring the actual installation process, and typically cannot be quicklyrectified. Similarly, fairly significant labor and expertise (and thuscost) is required to install non-penetrating PV modules at a commercialbuilding's rooftop. Finally, considerable expense is necessitated by thehandling and disposal of the shipping materials required in providingall of the PV modules, as well as all of the auxiliary mountingcomponents and related equipment.

PV module-based solar energy represents an extremely promisingtechnology for reducing the reliance of commercial or industrialbusinesses upon conventional, natural resource-based energy. To becompetitive with traditional sources of municipal power, however, thecosts associated with solar PV systems should desirably be reducedwherever possible. Thus, a need exists for a PV module and related PVmodule systems or arrays that are readily mounted to commercial rooftopsin a non-penetrating fashion.

SUMMARY

Some aspects in accordance with principles of the present disclosurerelate to a photovoltaic (PV) module including a PV device and a frame.The PV device includes a PV laminate having a perimeter and a front facedefining a major plane. The frame is assembled to and encases theperimeter of the PV laminate. In this regard, the frame includesopposing, leading and trailing frame members, and opposing, first andsecond side frame members. Further, an arm is provided that projectsfrom one of the frame members and forms a support face opposite thefront face of the PV laminate, with the support face being adapted forplacement against a separate installation surface, thereby supportingand orienting the PV laminate relative to the installation surface. Withthis in mind, a plane of the support face and the major plane of the PVlaminate are non-parallel (e.g., the PV laminate is tilted relative tothe support face). Regardless, upon final assembly (e.g., factoryassembly), the PV laminate and the frame combine to define a unitarystructure. In some embodiments, the frame is configured such that whenthe support face is placed on a flat surface, the PV laminate isoriented at a non-parallel angle relative to the flat surface, forexample, at an angle in the range of 3°-7°. In other embodiments, theunitary structure feature of the PV module entails that the frame cannotbe disassembled from the PV laminate without destroying at least one ofthe frame members. In yet other embodiments, the frame members areentirely formed of a polymeric material. In yet other embodiments, oneor more of the frame members incorporates integral features thatfacilitate interconnection with corresponding features of a second,identically formed PV module.

Other aspects in accordance with principles of the present disclosurerelate to a method of manufacturing a PV module. The method includesproviding a PV device including a PV laminate having a perimeter at afront face defining a major plane. A frame is also provided includingleading, trailing, and first and second side frame members. Further, theframe includes an arm projecting from one of the frame members anddefining a support face. The PV laminate is mounted to the frame memberssuch that the frame members encase the perimeter. Further, the framemembers are mounted to one another. Upon final assembly (e.g., factoryassembly), the PV laminate and the frame combine to define a unitarystructure, with a plane of the support face and the major plane of thePV laminate being non-parallel. In some embodiments, the frame membersare simultaneously mounted to one another and the PV laminate, therebysimplifying the overall manufacturing process.

Other aspects in accordance with principles of the present disclosurerelate to a photovoltaic module system kit for non-penetratinginstallation at a substantially flat surface, such as a commercialbuilding rooftop. The system kit has at least two PV modules eachincluding a PV device and a frame. The PV device includes a PV laminate.The frame is assembled to and surrounds the PV laminate to define aunitary structure. Further, the frame includes an arm forming a planarsupport face for placement against a separate installation surface so asto tilt the PV laminate relative to the installation surface. Thesupport face and the PV laminate are non-parallel to effectuate tiltedarrangement upon non-penetrating installation to a flat rooftop. In kitform appropriate for shipping, the frame of the first PV module isnested on top of the frame of the second PV module, whereby the arm(s)carried by the frames do not impede the nested relationship.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a top, rear perspective view of a photovoltaic module inaccordance with principles of the present disclosure;

FIG. 1B is an exploded view of the photovoltaic module of FIG. 1A;

FIG. 2 is a side view of the photovoltaic module of FIG. 1A mounted toan installation surface;

FIG. 3A is an exterior, perspective view of a portion of a frame usefulwith the photovoltaic module of FIGS. 1A and 1B;

FIG. 3B is an interior plan view of the frame portion of FIG. 3A;

FIG. 3C is an enlarged, perspective view of a segment of the frameportion of FIGS. 3A and 3B;

FIG. 3D is a simplified, cross-sectional view of the frame portion ofFIGS. 3A and 38;

FIG. 3E illustrates assembly of a photovoltaic laminate to the frameportion of FIG. 3D;

FIG. 4A is an exterior, perspective view of portions of the frame ofFIG. 1B prior to assembly;

FIG. 4B is an interior, perspective view of the frame portions of FIG.4A;

FIG. 5 is a side view of the photovoltaic module of FIG. 1A, includingwiring associated therewith;

FIG. 6 is an interior, elevated perspective view of a portion of thephotovoltaic module of FIG. 1A;

FIG. 7 is a top, perspective view of a portion of a photovoltaic modulearray in accordance with principles of the present disclosure;

FIG. 8 is a side view of the array of FIG. 7;

FIG. 9 is a top view of the array of FIG. 7;

FIG. 10 is a rear perspective view of multiple ones of the modules ofFIG. 1A provided as a stacked system; and

FIG. 11 is a rear perspective view of photovoltaic modules in accordancewith the present disclosure stacked relative to one another andincorporating a wind deflector component.

DETAILED DESCRIPTION

One embodiment of a photovoltaic (PV) module 20 in accordance withprinciples of the present disclosure is shown in FIGS. 1A and 1B. The PVmodule 20 includes a PV device 22 (referenced generally) and a frame 24.Details on the various components are provided below. In general terms,however, the PV device 22 includes a PV laminate 26 that is encased bythe frame 24. In this regard, the frame 24 provides one or more supportfaces that effectuate a tilted orientation of the PV laminate 26relative to a flat installation surface (e.g., a flat rooftop). Further,in some embodiments, the frame 24 incorporates one or more features thatfacilitate mounting of the PV module 20 to one or more similarlyconstructed PV modules. Regardless, the frame 24 and the PV laminate 26are assembled to one another to form or define a unitary structure. Withthis configuration, the PV module 20 is highly amenable tonon-penetrating, commercial rooftop installations in which a minimalnumber of additional parts are required for effectuating mounting ofmultiple ones of the PV modules 20 as part of a PV system array. This,in turn, greatly simplifies the installation process, for example interms of labor, parts, and upfront planning, while greatly reducingshipping and handling costs. Benefits are realized in the installationof the PV modules 20 to any substantially flat surface (e.g., maximumpitch of 2:12), including commercial rooftop, residential rooftop, andground mount applications.

The PV device 22, including the PV laminate 26, can assume a widevariety of forms currently known or in the future developed appropriatefor use as a solar photovoltaic device. In general terms, the PVlaminate 26 consists of an array of photovoltaic cells. A glass laminatemay be placed over the photovoltaic cells for environmental protection.In some embodiments, the photovoltaic cells advantageously comprisebackside-contact cells, such as those of the type available fromSunPower Corp., of San Jose, Calif. As a point of reference, inbackside-contact cells, wirings leading to external electrical circuitsare coupled on the backside of the cell (i.e., the side facing away fromthe sun upon installation) for increased area for solar collection.Backside-contact cells are also disclosed in U.S. Pat. Nos. 5,053,083and 4,927,770, which are both incorporated herein by reference in theirentirety. Other types of photovoltaic cells may also be used withoutdetracting from the merits of the present disclosure. For example, thephotovoltaic cells can incorporate thin film technology, such as siliconthin films, non-silicon devices (e.g., III-V cells including GaAs), etc.Thus, while not shown in the figures, in some embodiments the PV device22 can include one or more components in addition to the PV laminate 26,such as wiring or other electrical components.

Regardless of an exact construction, the PV laminate 26 can be describedas defining a front face 30 and a perimeter 32 (referenced generally inFIGS. 1A and 1B). As a point of reference, additional components (whereprovided) of the PV device 22 are conventionally located at or along aback face of the PV laminate 26, with the back face being hidden in theview of FIGS. 1A and 1B.

With the above understanding of the PV device 22, and in particular thePV laminate 26, in mind, the frame 24 includes a leading frame member40, a trailing frame member 42, a first side frame member 44, and asecond side frame member 46. As described below, the frame 24incorporates one or more additional features that facilitate arrangementof the PV laminate 26 at a desired orientation (e.g., tilted) relativeto a substantially flat surface such as a rooftop. By way of furtherexplanation, FIG. 2 provides a simplified illustration of the PV module20 relative to a relatively flat, horizontal surface S. Though hidden inthe view of FIG. 2, a location of the PV laminate 26 is generallyindicated, as is a plane P_(PV) of the PV laminate 26 that is otherwiseestablished by the front face 30 (FIGS. 1A and 1B). With this in mind,and relative to the arrangement of FIG. 2, the frame 24 supports the PVlaminate 26 relative to the flat surface S at a slope or tilt angle θ.The tilt angle θ can otherwise be defined as an included angle formedbetween the PV laminate plane P_(PV) and a plane of the flat surface S.With this in mind, the frame 24 is configured to support the PV laminate26 at a tilt angle θ in the range of 1°-30°, in some embodiments in therange of 3°-7°, and yet other embodiments at 5°. As a point ofreference, with tilted PV solar collection installations, the PVlaminate 26 is desirably positioned so as to face or tilt southward (innorthern hemisphere installations). Given this typical installationorientation, then, the leading frame member 40 can thus be generallyreferred to as a south frame member, and the trailing frame member 42referred to as a north frame member. Returning to FIGS. 1A and 1B, andconsistent with these directional designations, the first side framemember 44 can be referred to as a west frame member, whereas the secondside member 46 can be referred to as an east frame member.

The frame members 40-46 can assume a variety of forms appropriate forencasing the perimeter 32 of the PV laminate 26, as well as establishingthe desired tilt angle θ (FIG. 2). In some embodiments, the framemembers 40-46 are separately formed, and subsequently assembled to oneanother and the PV laminate 26 in a manner generating a unitarystructure upon final construction.

Each of the frame members 40-46 can incorporate, in some embodiments,identical features that promote assembly to the PV laminate 26. FIGS. 3Aand 3B illustrate examples of these features relative to the first sideframe member 44. In particular, the first side frame member 44 generallyincludes a frame body 50 and a bracket assembly 52. The frame body 50can assume a variety of forms or shapes, and in some embodiments is akinto an I-beam in cross-section as reflected in FIG. 3A. Regardless, thebracket assembly 52 projects upwardly (relative to the orientation ofFIGS. 3A and 3B) from the frame body 50 and includes a C-shaped bracket60 that defines or is defined by a lower surface 62, an upper surface64, and an end surface 66. The lower surface 62 is formed proximate theframe body 50, and the upper surface 64 is formed opposite the lowersurface 62. The end surface 66 interconnects the lower and uppersurfaces 62, 64, with the surfaces combining to define a channel 68sized to receive the PV laminate 26 (FIG. 1B). More particularly, thechannel 68 is sized to receive a corresponding edge of the PV laminate26, and an appropriate adhesive employed to permanently affix or bondthe PV laminate 26 to the bracket 60.

A spacing between the lower and upper surfaces 62, 64 can be greaterthan an expected height or thickness of the PV laminate 26 (FIG. 1B),with the bracket assembly 52 further including a plurality of spacedguide features 70 adapted to centrally maintain the PV laminate 26between the surfaces 62, 64 in some embodiments. One of the guidefeatures 70 is shown in greater detail in FIG. 3C, and includes a lowerguide tab 72 a projecting from the lower surface 62, and an upper guidetab 72 b projecting from the upper surface 64. The guide tabs 72 a, 72 bcan be vertically aligned and having an increasing height or thicknessin extension toward the end surface 66 as reflected by FIG. 3D. Thus, ina region of guide tabs 72 a, 72 b, the channel 68 tapers in height froman open end 74 to the end surface 66.

By correlating the guide tabs 72 a, 72 b with an expected thickness ofthe PV laminate 26, the bracket assembly 52 is adapted to quicklyreceive, and desirably position, the PV laminate 26 relative to thebracket 60 for subsequent adhesive bonding as shown in FIG. 3E. As apoint of reference, FIG. 3E represents the PV laminate 26 in simplifiedform, and the PV laminate 26 can have various features not specificallyillustrated but accounted for by the guide features 70 (e.g., the PVlaminate 26 can taper in thickness toward the perimeter edge).Regardless, the PV laminate 26 is maintained within the channel 68, viathe guide tabs 72 a, 72 b, at an off-set or spaced position relative tothe surfaces 62-66. This off-set provides sufficient spacing within thechannel 68 for receiving and maintaining an adequate volume of adhesive(not shown), such as an RTV silicone adhesive, otherwise used to bondthe PV laminate 26 to the bracket 60 (and in particular the surfaces62-66), with the PV laminate 26 being centered between the lower andupper surfaces 62, 64 in some embodiments.

Returning to FIGS. 3B and 3C, one or more of the frame members 40-46(FIG. 1A) can include additional features that promote assembly with thePV laminate 26. For example, with respect to the first side frame member44, the bracket assembly 52 can further include one or more ramps 80.The ramps 80 are laterally spaced from one another (e.g., aligned withrespective ones of the guide features 70), and provide a ramp surface 82extending from the frame body 50 to the lower surface 62 of the bracket60. More particularly, the ramp surface 82 extends in an angular fashiondownwardly and away from the lower surface 62, and provides a surfacefor guiding the PV laminate 26 (FIG. 3D) into the channel 68. Thus,assembly of the PV laminate 26 entails sliding an edge of the PVlaminate along the surface 82 of the ramp(s) 80, with the ramp surface82 directing the PV laminate 26 into the channel 68 via respective onesof the lower guide tabs 72 a (FIG. 3C) as described above.Alternatively, a wide variety of other configurations can be employed tofacilitate assembly of the frame 24 and the PV laminate 26 such that oneor more of the above-described features can be omitted.

Returning to FIG. 1B, one or more or all of the frame members 40-46 canincorporate the I-beam shaped (or other shape) frame body 50 and/orbracket assembly 52 (FIG. 3A) described above. In addition, in someembodiments, the frame members 40-46 include or form connector fittingsadapted to facilitate robust interconnection or assembly of the framemembers 40-46 to one another. For example, the leading and trailingframe members 40, 42 can include or form identically, opposing maleconnectors 100, 102 (identified for the trailing frame member 42 in FIG.1B), whereas each of the side frame members 44, 46 includes or formsopposing, first and second female connectors 104, 106 (identified forthe first side frame member 44 in FIG. 113). In general terms, each ofthe female connectors 104, 106 are configured to receive a correspondingone of the male connectors 100, 102 in a press fit-type relationship.Notably, the connector type (i.e., male or female) associated with eachof the frame members 40-46 can vary (e.g., the leading frame member 40can form two female connectors, or one female connector and one maleconnector) so long as a male/female connection pair is established ateach of the frame member 40-46 intersections.

One embodiment of male and female connectors useful with the presentdisclosure is shown in FIGS. 4A and 4B, and in particular the maleconnector 100 of the trailing frame member 42 and the female connector104 of the first side frame member 44. As illustrated, the male andfemale connectors 100, 104 have an identical shape, with the femaleconnector 104 forming a receptacle 110 within which the male connector100 is received. The corresponding shape associated with the connectors100, 104 is generally cross-like, including a first segment 112 and asecond segment 114 (identified for the male connector 100 in FIG. 4A).The segments 112, 114 extend in an approximately perpendicular fashionrelative to one another, with the second segment 114 bisecting the firstsegment 112 in some embodiments. To provide enhanced support of theframe members 42, 44 relative to an interior of the frame 24 (i.e., alocation of the PV laminate 26 (FIG. 1A)), the second segment 114 has anelongated, interior extension portion 116 (relative to the first segment112). Further, in some constructions, at least the second segment 114tapers in width from a base end 120 to a free end 122. Stated otherwise,a horizontal dimension of the second segment 114 at the base end 120 isgreater than that at the free end 122. With this tapered construction,along with a corresponding shape defined by the female connectors 104 or106, the male connector 100 is readily insertable into the receptacle110 of the female connector 104. As the male connector 100 is furtherforced into the receptacle 110 (and/or vice-versa), a tapered press fitjunction is achieved whereby the male connector 100 is frictionallylocked within the female connector 104.

Returning to FIGS. 1A and 1B, the frame 24 can incorporate other designsto facilitate robust assembly of the frame members 40-46. However, atleast with embodiments in which the frame members 40-46 aresimultaneously assembled to the PV laminate 26 (via an adhesive) and toone another (e.g., via the connectors 100-106), the resultant assemblyincludes the PV laminate 26 and the frame 24 combining to define aunitary structure, with the frame members 40-46 completely “capturing”the PV laminate 26. As used through this specification, a “unitarystructure” is in reference to a robust, unchanging assembly whereby theframe 24 cannot be disassembled from the PV laminate 26 withoutdestroying at least one of the frame members 40-46. Notably, noadditional components or specialized tools are required to effectuatecomplete, final assembly of the frame 24 and the PV laminate 26 inaccordance with the above configurations. This presents significantsavings in installation time as installers are not required to assemblecomponent parts at the installation site to “complete” an individual PVmodule.

In addition to the frame members 40-46 described above, in someembodiments the frame 24 further includes one or more arms thatfacilitate desired orientation of the PV laminate 26 relative to aninstallation surface, as well as mounting of two or more PV modules 20to one another. For example, in some embodiments, the frame 24 includesa first arm 130, a second arm 132, a third arm 134, and a fourth arm136. The arms 130-136 can be formed by or otherwise associated withvarious ones of the frame members 40-46; with the construction of FIGS.1A and 1B, for example, the first and third arms 130, 134 are providedas opposing extensions of (or from) the first side frame member 44,whereas the second and fourth arms 132, 136 are provided as opposingextensions of (or from) the second side frame member 46. Upon finalassembly of the frame 24, the first and second arms 130, 132 project orextend longitudinally beyond (e.g., forward) the leading frame member40, whereas the third and fourth arms 134, 136 project or extendlongitudinally beyond (e.g., rearward) the trailing frame member 42 asshown in FIG. 1A.

The first and second arms 130, 132 can be of an identical construction,defining mirror images upon final construction of the frame 24. Withthis in mind, FIG. 1B illustrates the first arm 130 as including ordefining a side wall 140 and a flange 142. The flange 142 projectsinwardly from the side wall 140 along a perimeter thereof. The flange142 effectively defines an overall width of the first arm 130. Further,extension of the flange 142 relative to the side wall 140 forms amounting region 144 adapted to promote mounting with an arm (not shown)of a second PV module 20 as described below, with the mounting region144 including or forming a bore 146 through the side wall 140.Regardless, the mounting region 144 is located longitudinally beyond (oris spaced from) not only the first side frame member 44, but also theleading frame member 40. This relationship is best reflected in FIG. 5relative to the mounting region 144 of the second arm 132 relative tothe leading frame member 40 (referenced generally).

Additional optional features of the first and second arms 130, 132 arefurther described with reference to FIG. 5, and in particular withrespect to the second arm 132 that is otherwise visible in the view ofFIG. 5. As shown, the second arm 132 extends outwardly and downwardlyfrom the second side frame member 46 (and thus the leading frame member40 that is otherwise generally referenced in FIG. 5). More particularly,forward (i.e., leftward relative to the orientation of FIG. 5) extensionof the second arm 132 terminates at a leading surface 150. The leadingsurface 150 (along with an identical surface of the first arm 130 (FIG.1B)) serves as the forward-most end of the frame 24, and thus of the PVmodule 20. As described below, this forward extension or dimension,along with the longitudinal positioning of the mounting region 144, isselected to correspond with a dimension of the fourth arm 136 (and amounting region formed thereby) in establishing a desired end-to-endassembly of two PV modules 20. It will be understood that a similarrelationship is established between the first arm 130 (FIG. 1B) and thethird arm 134 (FIG. 1B) (again, as between two PV modules 20 positionedend-to-end).

Similarly, downward extension of the second arm 132 from the second sideframe member 46 terminates at a bottom surface 152. The bottom surface152 (along with an identical surface of the first arm 130 (FIG. 1B), aswell as with one or more surfaces provided by the third and fourth arms134, 136 as described below) serves as a bottom-most surface of theframe 24 and provides a support face at which the PV module 20 issupported relative to an installation surface. More particularly,downward extension of the first and second arms 130, 132 is selected inaccordance with selected dimensional attributes of the third and fourtharms 134, 136 (described in greater detail below) to collectively createor define a common support face (e.g., including the bottom surface 152)that in turn dictates the desired, tilted orientation of the PV laminate26 on a flat installation surface as mentioned above.

Returning to FIG. 1B, the third and fourth arms 134, 136 have anidentical construction in some embodiments, forming mirror images of oneanother upon final construction of the frame 24. With this in mind,certain features of the third aim 134 are illustrated in FIGS. 3A and3B. The third arm 134 can be L-shaped, and includes a shoulder 160 and afoot 162. The shoulder 160 can be formed with, and extends downwardlyfrom and beyond, the first side frame member 44. As illustrated, asupportive interface between the shoulder 160 and the first side framemember 44 (and in particular the frame body 50) is established along alength of the first side frame member 44, proximate a trailing end 164thereof. In this regard, downward extension of the shoulder 160 (as wellas positioning of the foot 162 as described below) is such that aninterior-most face 166 of the shoulder 160 is laterally offset from anexterior-most face 168 of the first side frame member 44. That is tosay, an entirety of the portion of the third arm 134 extending from thefirst side frame member 44 is spatially positioned to the side of andaway from the first side frame member 44. For reasons made clear below,this optional arrangement promotes desired spacing between two PVmodules 20 when arranged side-by-side. Further, the transversely offsetposition of the third arm 134 (and the fourth arm 136) facilitatednested, stacked arrangement of multiple ones of the PV modules 20, forexample during shipping and/or storage. Along these same lines, and asbest shown in FIG. 6, the interior-most face 166 of the shoulder 160(extending beyond the first side frame member 44) can form a trough 170that further facilitates stacked, nested arrangements.

Returning to FIGS. 3A and 3B, the foot 162 extends rearwardly from theshoulder 160 and forms a mounting region 180, a lower surface 182, andan upper surface 184. The mounting region 180 is defined at a spatiallocation that is longitudinally spaced from the first side frame member44 (and thus longitudinally spaced from the trailing frame member 42upon final construction as shown in FIG. IA). More particularly,longitudinal extension of the foot 162 from the shoulder 160 spatiallypositions the mounting region 180 rearward of not only the first sideframe member 44, but also the trailing frame member 42. The selectedextension dimensions of the foot 162 (and in particular the spatialcoordinates of the mounting region 180) correlates with the extensiondimensions associated with the first arm 130 (and in particular thespatial coordinates of the mounting region 144 (FIG. 1B)) as describedabove to establish desired, end-to-end spacing of two of the PV modules20 when mounted to one another (it being understood that an identicalrelationship is established between the second and fourth arms 132,136). With this in mind, the mounting region 180 can include a bore 190extending between an interior face 192 and an exterior face 194.

Returning to FIG. 5, the lower surface 182 is relatively planar along alength of the foot 162, and establishes a desired orientation of the PVlaminate 26 (referenced generally) via arrangement of the fourth arm 136in extension from the second side frame member 46 (it being recalledthat the third arm 134 (FIGS. 3A and 3B) has an identical constructionin some embodiments). In particular, the lower surface 182 serves as apart of the PV module support face described above, and defines a planeP_(A) that is non-parallel relative to the plane P_(PV) of the PVlaminate 26 (as otherwise spatially maintained by the frame members40-46). Further, the plane P_(A) of the lower surface 182 (as well asthe identical plane defined the lower surface of the third arm 134intersects the bottom surface 152 of the second arm 132 (as well as theidentical bottom surface of the first arm 130 (FIG. 1B)). Thus, the arms130-136 combine to spatially establish the desired, tilted orientationof the PV laminate 26 relative to a flat installation surface.

As mentioned above, the shoulder 160 extends from a point along a lengthof the corresponding side frame member 44, 46 (e.g., the second sideframe member 46 in the view of FIG. 5). With this in mind, the foot 162forms the upper surface 184 to be spaced below the second side framemember 46 (as well as below the trailing frame member 42). Thus, theupper surface 184, the shoulder 160, and the second side frame member 46combine to define a gap 200 (referenced generally in FIG. 5). The gap200 provides a highly convenient, protected area along which wiring 202(e.g., east-west wiring) associated with the PV device 22 (as well aswiring from other PV modules 20 assembled in an array) can be placedwithout the cumbersome need to route wires under each PV module as isotherwise required with conventional designs. In this regard, the wiring202 can be placed on to, and safely maintained by, the upper surface184.

Usefulness of the arm configurations described above in facilitatingmounting of two or more of the PV modules 20 to one another can bedescribed with reference to FIG. 7. In particular, FIG. 7 illustratesrelevant portions of four, identically-constructed ones of the PVmodules 20 in accordance with the present disclosure, including PVmodules 20 a-20 d mounted in an array 210. The first and second PVmodules 20 a, 20 b are mounted to one another in an end-to-endrelationship, as are the third and fourth PV modules 20 c, 20 d. Inaddition, the first and third PV modules 20 a, 20 c are mounted to oneanother in a side-by-side relationship, as are the second and fourth PVmodules 20 b, 20 d.

Mounting of the first and second PV modules 20 a, 20 b includes thefirst arm 130 a of the first PV module 20 a mounted to the third arm 134b of the second PV module 20 b, and the second arm 132 a of the first PVmodule 20 a mounted to the fourth arm 136 b of the second PV module 20b. Similar mounting relationships are established between the first arm130 c of the third PV module 20 c and the third arm 134 d of the fourthPV module 20 d, as well as the second arm 132 c and the fourth arm 136d. Finally, the fourth arm 136 b of the second PV module 20 b is mountedto the third arm 134 c of the third PV module 20 c.

To effectuate a more complete mounting between the respective arm pairs(e.g., the arms 130 a/ 134 b), a coupling device 220 (referencedgenerally) can be provided, for example including a bolt component 222and a nut component 224. More particularly, upon arrangement ofrespective ones of the PV modules 20 in an end-to-end relationship(e.g., the first and second PV modules 20 a, 20 b), the mounting regionsof the corresponding arm pairs (e.g., the mounting region 144 a of thefirst arm 130 a and the mounting region 180 b (referenced generally) ofthe third arm 134 b) are naturally or intuitively positioned by aninstaller such that the respective bores 146 (FIG. 1B), 190 (FIG. 3A)are aligned for commonly receiving the bolt 222. Further, the arms130-136 are configured such that the bottom surface 152 of the first orsecond arm 130 or 132 is aligned or co-planar with the lower surface 182of the corresponding third or fourth arm 134 or 136. For example, andwith additional reference to FIG. 8, the bottom surface 152 of thesecond arm 132 c of the third PV module 20 c is aligned with the lowersurface 182 of the fourth arm 136 d of the fourth PV module 20 d.Similar, aligned relationships are established at the other arm mountinginterfaces, such as the arm mounting interface 130 a/ 134 b, 132 a/ 136b, and 130 c/ 134 d. With this construction, then, in the mountedarrayed arrangement 210 of FIGS. 7 and 8, the PV laminates 26 a-26 d areall oriented at virtually identical tilt angles; the commonly, spatiallypositioned surfaces 152, 182 of the various arms 130-136 dictate thatregardless of the number of PV modules 20 within the array 210 andregardless of the number of PV modules 20 mounted to an individual PVmodules 20 (including a single, standing-alone PV module 20), desiredtilted orientation of the corresponding PV laminates 26 in consistentlyprovided with a straightforward installation process. Along these samelines, by interconnected the PV modules 20 to one another, the array 210can quickly be installed on a rooftop without requiringrooftop-penetrating components or any specialty tools.

The simplified array 210 is but one example of a PV module installationfacilitated by the present disclosure. The PV module 20 constructions ofthe present disclosure allow for virtually any array installationconfiguration (e.g., in terms of number of PV modules 20 mounted to oneanother on a substantially flat commercial rooftop and/or overall“shape” or geometry of the resultant array). Regardless of theparameters of the desired array, the individual PV modules 20 are simplyand quickly mounted to one another as described above, and can be placedat any location within the array. Thus, the PV module 20 has a universalconfiguration. East-west wiring (or other wiring) can be run “beneath” aline of mounted PV modules 20 as described above (e.g., in FIG. 5).Simplified, consistent arrangement of other wiring, such as “home run”wiring (e.g., north-south wiring or east-west wiring), is alsofacilitated by features of the PV modules 20 of the present disclosure.For example, as reflected in FIG. 9, that otherwise provides a top viewof the array 210, the side-by-side arranged PV modules 20 a, 20 c and 20b, 20 d define a longitudinal gap 230 relative to the corresponding PVlaminates 26 a-26 d. More particularly, the above-described, laterallyoff-set position of the third and fourth arms 134, 136 of each of the PVmodules 20 (e.g., the fourth arm 136 b of the second PV module 20 b andthe third arm 134 d of the fourth PV module 20 d in FIG. 9) creates thelongitudinal gap 230 when the PV modules 20 are disposed side-by-side.Wiring can be run along the longitudinal gap 230, maintained away fromor “above” the rooftop surface by placement on the upper surface 184associated with each of the arms 134, 136. For both east-west andnorth-south wiring, the above construction eliminates the need fortime-consuming and cumbersome routing of wires underneath individual PVmodules. Rather, the installer can simply walk along or through thearray 210 and place wiring as necessary without needing to lift the PVmodules 20 and/or routing wires under the PV modules 20.

As is evident from the above, the PV modules 20 of the presentdisclosure greatly simplify the rooftop installation process. Minimalon-site assembly is required in installing an array of tilted,non-penetrating PV solar tiles. An additional advantage is recognized inthe context of upfront planning. Because the PV module 20 caneffectively be installed (non-penetrating) “as is,” the upfrontinstallation planning process essentially entails the step of orderingthe number of PV modules 20 determined to be necessary for a particularinstallation site. Unlike conventional commercial rooftop PV solar tileformats, installers of PV modules 20 of the present disclosure are notrequired to estimate the number and type of auxiliary installationcomponent parts ahead of time and hope that the correct estimate is made(and that the correct component parts are actually delivered). In fact,each PV module 20 can be provided to the installation site in a kitform, including the PV module 20 and a standard number of the couplingdevices 220 (FIG. 7) and, an optionally, a wind deflector. With thiskilted form, the installer has all components necessary to install thePV module array, regardless of the number of PV modules 20 to beinstalled and/or the actual “shape” of the desired array. While it isrecognized that some installation sites may require additionalcomponents (e.g., ballast), the desired quantities of these componentsare more readily estimated (as compared to auxiliary installationcomponent parts with conventional tilted, non-penetrating rooftop PVsolar tiles), such that upfront planning is greatly eased with thepresent disclosure. Further, the PV modules 20 can include optionalfeatures that facilitate assembly of the common components such as winddeflectors and/or ballast.

In addition to promoting simplified, rapid installation, features of thePV modules 20 of the present disclosure greatly reduce packaging andshipping expenses. Returning to FIGS. 1A and 1B, in some embodiments theframe 24 is formed entirely of plastic or polymeric material(s). Forexample, the frame 24, and in particular the frame members 40-46 andarms 130-136, are molded polymeric components, such as injection moldedPPO/PS (Polyphenylene Oxide co-polymer/polystyrene blend) or PET(Polyethylene Terephthalate), although other polymeric or electricallyinsulating material(s) are also acceptable. The resultant PV module 20is lightweight (e.g., on the order of 3 lbs/ft²), and thereforerelatively inexpensive to install and presents minimal rooftop loadingconcerns. Further, as compared to conventional PV module constructionsthat rely primarily upon metal framework and related installationcomponents, the PV modules 20 of the present disclosure incorporatingthe optional non-conductive plastic frame 24 do not require additionalgrounding components (and related installation procedures).Alternatively, however, the frame 24 can be partially or entirely formedof metal.

Regardless of the material(s) used in forming the frame 24, identicallyformed ones of the PV modules 20 can be compactly arranged for shippingto an installation site. For example, FIG. 10 illustrates three of thePV modules 20 e-20 g of the present disclosure stacked in a nestedarrangement as part of a kitted system 240. The frame members 40 e-46 eof the first PV module 20 e abut against the corresponding frame members40 f-46 f of the second PV module 20 f (it being understood that theleading frame members 40 and the first side frame members 44 are hiddenin the view of FIG. 10); a similar arrangement is established betweenthe frame members 40 f-46 f of the second PV module 20 f and the framemembers 40 g-46 g of the third PV module 20 g. The laterally off-setarrangement of the corresponding third and fourth arms 134, 136 promotethis stacked assembly. For example, the third and fourth arms 134 e, 136e of the first PV module 20 e “clear” the frame 24 f of the second PVmodule 20 f in placing the frame 24 e of the first PV module 20 e ontothe frame 20 f of the second PV module 20 f. Notably, the trough 170associated with each of the third and fourth arms 134, 136 as describedabove with respect to FIG. 6 further promotes the stacked, nestedarrangement of the PV modules 20 e-20 g. For example, the shoulder 160of the fourth arm 136 f of the second PV module 20 f is slidablyreceived within the trough 170 (hidden in FIG. 10) of the fourth arm 134e of the first PV module 20 e. As a result, the PV modules 20 of thepresent disclosure can be closely stacked for high shipping density,thereby greatly minimizing shipping (and related packaging) waste andcost. Notably, this same, nested or stacked arrangement is also achievedwith shipping formats including additional components such as a winddeflector 250 as shown in FIG. 11. More particularly, respective ones ofthe wind deflector 250 are assembled to each of the PV modules 20 e-20 gso as to extend between the corresponding trailing frame member 42 andthird/fourth arms 134/136 (e.g., the wind deflector 250 e is assembledto the trialing frame member 42 e and the third/fourth arms 134 e/ 136 eof the first PV module 20 e) in a manner that does not impeded thedesired, stacked arrangement in a kilted system.

The PV modules of the present disclosure provide a marked improvementover previous designs. The frame allows for simple, rapid,non-penetrating installation of a PV module array to a flat commercialrooftop, with the corresponding PV laminate desirably being arranged ata tilted orientation. Further, the unitary construction of the frame andPV device (and in particular the PV laminate) greatly reduces ordering,shipping, and handling steps and expenses in a manner not previouslyconsidered possible. In sum, the PV modules of the present disclosureaddress most, if not all, of the drawbacks associated with conventionalnon-penetrating, tilted PV solar tile installations, thereby enhancingmarket viability of this environmentally imperative energy technology.

Although the present disclosure has been described with reference topreferred embodiments, workers skilled in the art will recognize thatchanges can be made in form and detail without departing from the spiritand scope of the present disclosure. For example, while the frame hasbeen described as including four of the arms, in other embodiments, alesser or greater number can be provided. Along these same lines, whilethe various arms have been described as being formed as part of certainframe members (e.g., the side frame members), in other embodiments, oneor more of the arms can project from (or be formed as part of) other(s)of the frame members.

What is claimed is:
 1. A photovoltaic module system kit fornon-penetrating installation at a substantially flat surface, the kitcomprising: first and second photovoltaic modules each including: aphotovoltaic device including a photovoltaic laminate, and a frameassembled to and surrounding the photovoltaic laminate to define aunitary structure, the frame including an arm integral with the frameand forming a planar support face for placement against a separateinstallation surface, wherein the kit is configured to provide a storagestate in which the frame of the first photovoltaic module is placedagainst the frame of the second photovoltaic module such that therespective photovoltaic laminates are parallel, the arm of the firstphotovoltaic module being transversely off-set from the frame of thesecond photovoltaic module, wherein the storage state further includesthe arm of the second photovoltaic module received within a trough ofthe arm of the first photovoltaic module.
 2. The kit of claim 1, furthercomprising: a first coupling device associated with the firstphotovoltaic module for mounting of the first photovoltaic module aspart of a non-penetrating array; and a second coupling device associatedwith the second photovoltaic module for mounting of the secondphotovoltaic module as part of a non-penetrating array; wherein thefirst and second coupling devices are identical.
 3. The kit of claim 2,wherein the coupling site of the adjacent photovoltaic module is an armof a frame of the adjacent photovoltaic module.
 4. The kit of claim 1,wherein the frame is configured such that when the planar support faceis installed on a flat surface of the separate installation surface, amajor plane of the photovoltaic laminate is oriented at a non-parallelangle relative to the flat surface.
 5. The kit of claim 1, wherein, uponfinal assembly, the photovoltaic laminate and the frame combine todefine a unitary structure, and wherein the unitary structure isconfigured such that the frame cannot be disassembled from thephotovoltaic laminate without destroying the frame.
 6. The kit of claim1, wherein the frame is formed of a polymeric material.
 7. The kit ofclaim 1, wherein the frame comprises a frame member that is I-shaped incross-section.
 8. The kit of claim 1, wherein the frame comprises afirst side frame member and a trailing frame member, and wherein thefirst side frame member includes a first connector configured forpress-fit assembly with a corresponding, second connector of thetrailing frame member.
 9. The kit of claim 8, wherein: the firstconnector is one of: a female component defining a receptacle, a malecomponent having a shape corresponding with a shape of the receptacle;and the second connector is another of the male and female components.10. The kit of claim 9, wherein the male component includes first andsecond segments, the segments intersecting one another and beingapproximately perpendicular.